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YAMAHA 



TDM850 



'97 



4TX-AE2 



SUPPLEMENTARY 

SERVICE MANUAL 



FOREWORD 



This Supplementary Service Manual has been prepared to introduce new service and data for the TDM850 
'97. For complete service information procedures it is necessary to use this Supplementary Service Manual 
together with the following manual. 



TDM850 '96 SERVICE MANUAL: 4TX-AE1 



TDM850 '97 

SUPPLEMENTARY 

SERVICE MANUAL 

© 1996 by Yamaha Motor Co., Ltd. 

First Edition, October 1996 All rights 

reserved. 

Any reproduction or unauthorized use 

without the written permission of 

Yamaha Motor Co., Ltd. 

is expressly prohibited. 



NOTICE 

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their 
qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is 
assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has 
a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted 
by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. 

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant 
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear 
in future editions of this manual where applicable. 

NOTE: 

Designs and specifications are subject to change without notice. 



IMPORTANT INFORMATION 

Particularly important information is distinguished in this manual by the following notations. 



A 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY 
IS INVOLVED! 



A WARNING 



Failure to follow WARNING instructions could result in severe injury or death to the 
motorcycle operator, a bystander or a person inspecting or repairing the motor- 
cycle. 



CAUTION: 



A CAUTION indicates special precautions that must be taken to avoid damage to 
the motorcycle. 



NOTE: 



A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

MANUAL ORGANIZATION 

This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols".) 

1 st title (T): This si the title of the chapter with its symbol in the upper right corner of each page. 

2nd title (2) : This title indicates the section of the chapter and only appears on the tirst page of each section . 
It is located in the upper left corner of the page. 

3rd title (3): This title indicates a sub-section that is followed by step-by-step procedures accompanied by 
corresponding illustrations. 

EXPLODED DIAGRAMS 

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal 
and disassembly section. 

1 . An easy-to-see exploded diagram is provided for removal and disassembly jobs. 

2. Numbers (5) are given in the order of the jobs in the exploded diagram. A number that is enclosed by 
circle indicates a disassembly step. 

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks©. The 
meanings of the symbol marks are given on the next page. 

4. A job instruction chart (?) accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. 

5. For jobs requiring more information, the step-by-step format supplements® are given in addition to the 
exploded diagram and the job instruction chart. 



® © 



® 



CLUTCH ENG 




/ 



^4J 



Order 


Jobn 


me /Part name 


Q'ty 


Remarks 




Crankcase co 


let (right) removal 




Remove the parts in the order below. 




Engmeoil 






Refer to "ENGINE OIL REPLACEMENT 
in CHAPTER 3. 




Clutch cable 








2 


Crankcase cov 
Gasket 


ar (right) 






Loosen the bolts in a cnssc.oss pattern. 






Dowel pin 




2 




5 












Plain washer 










Pull lever 


















' 


Plain washer 




' 


For installation, reverse the removal 
procedure. 



CLUTCH ENG 






• Glut 

• Glut 


i boss nut© 
hbo,.@) 


is; 


he clutch boss nut © while holding the 




1 §^y Universal clutch holder: 


:IS 


■ 


m?,"" 


■ 




INSPECTION 



.....,..:. . ■....■ 



i surface plate and feeler gauge (T). 



^y 



.-■■' 



■ Free length (clutch spring) (a) 


„,,. 


/M Free length (clutch spring): 



© 



GEN 
INFO 


#^ 



® 




INSP 
ADJ 


<$t 



COOL 


tt 



11 




13 




SPEC 



ENG 



% 



® 




CARB 


? 



® 




® 








CHAS 


Q^5& 


ELEC 


+ 


fn~\ 


© 






® 






TRBL 
SHTG 


9 

• 


dft 


© 






14 





18 



(1J ®) 

Q Q Q 



a 



New 



ILLUSTRATED SYMBOLS 

Illustrated symbols © to (9) are printed on top 
right of each page and indicate the subject of each 
chapter. 

(T) General information 

(2) Specifications 

(3) Periodic inspections and adjustments 

(4) Engine 

(5) Cooling system 

(6) Carburetion 

(7) Chassis 

(8) Electrical 

(9) Troubleshooting 



Illustrated symbols © to © are used to identify 
the specifications appearing in the text. 

@ Can be serviced with engine mounted 

@ Filling fluid 

@ Lubricant 

@) Special tool 

@ Torque 

@ Wear limit, clearance 

@ Engine speed 

<xh a V, A 



Illustrated symbols ® to @) in the exploded dia- 
grams indicate the types of lubricants and lubrica- 
tion points. 

@ Apply engine oil 

@) Apply gear oil 

@ Apply molybdenum disulfide oil 

@ Apply wheel bearing grease 

@) Apply lightweight lithium soap base grease 

@) Apply molybdenum disulfide grease 
Illustrated symbols @ to @) in the exploded dia- 
grams indicate where to apply a locking agent ® 
and when to install new parts @). 

@ Apply locking agent (LOCTITE®) 

@) Replace 



CONTENTS 

GENERAL INFORMATION 1 

MOTORCYCLE IDENTIFICATION 1 

VEHICLE IDENTIFICATION NUMBER 1 

MODEL LABEL 1 

SPECIFICATIONS 2 

GENERAL SPECIFICATIONS 2 

MAINTENANCE SPECIFICATIONS 3 

ENGINE 3 

CHASSIS 3 

ELECTRICAL 4 

CARBURETION 5 

CARBURETOR 5 

FUEL LEVEL ADJUSTMENT 5 

TDM850 '97 WIRING DIAGRAM 



MOTORCYCLE IDENTIFICATION 



GEN 
INFO 


(^•^ 







/ @^=- ;==::::: ^ ~x/r 


-—- 


(D"-" 


^^^ I 



GENERAL INFORMATION 
MOTORCYCLE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number © is stamped 
into the right side of the steering head. 




MODEL LABEL 

The model label © is affixed to the frame. 
This information will be needed to order spare 
parts. 



-1- 



GENERAL SPECIFICATIONS 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Model: 


TDM850 


Model code: 


4TX2 

5AR1 (CH,A) 


Dimensions: 
Overall length 
Overall width 
Overall height 
Seat height 
Wheelbase 

Minimum ground clearance 
Minimum turning radius 


2,200 mm 
790 mm 
1,285 mm 
805 mm 
1,475 mm 
165 mm 
2,900 mm 


Radiator: 
Radiator capacity (including all routes) 


1.7 L 


Tire: 
Type 
Size front 

rear 
Manufacturer front 

rear 
Type front 

rear 


Tubeless 
110/80 ZR18 
150/70 ZR17 

bridgestone'/pirelli/michelin 
bridgestoneVpirelli/michelin 
bt54f/mtr03/macadam 90x 
bt54r/mtr04/macadam 90x 

*ln Austria and Switzerland only Bridgestone 
tires are equipped on this mode. 



-2- 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Item 


Standard 


Limit 


Carburetor: 








I.D. mark 




5AR00(ForCH,A) 




Main jet 


(M.J) 


#142.5 




Main air jet 


(M.A.J) 


#60 




Jet needle 


(J.N) 


5EI85-2/3 




Needle jet 


(N.J) 


Y3 




Pilot air jet 1 


(P.A.J. 1) 


#70 




Pilot air jet 2 


(P.A.J.2) 


1.4 




Pilot outlet 


(P.O) 


0.9 




Pilot jet 


(P.J) 


#42.5 




Bypass 1 


(B.P.1) 


0.8 




Bypass 2 


(B.P.2) 


0.9 




Bypass 3 


(B.P.3) 


0.8 




Pilot screw 


(PS) 


2-1/2 




Valve seat size 


(V.S) 


1.7 




Starter jet 1 


(G.S.1) 


#75 




Starter jet 2 


(G.S.2) 


0.8 




Throttle valve size 


(Th.V) 


#130 




Fuel level 


(F.L) 


15.8 ~ 16.8 mm 




Engine idle speed 




1,100 ~ 1,200 r/min 




Intake vacuum 




36.0 ~ 38.7 kPa (270 ~ 290 mmHg) 





Tightening torques 



Part to be tightened 


Part name 


Thread 
size 


Q'ty 


Tightc 
tore 


jning 
ue 


Remarks 


Nm 


m»kg 


Muffler 


Bolt 


M10 


2 


30 


3.0 





CHASSIS 
Tightening torques 



Part to be tightened 


Thread 
size 


Tight* 
tore 


jning 
ue 


Remarks 


Nm 


m»kg 


Rear brake caliper and brake hose joint 


M10 


30 


3.0 





-3- 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



ELECTRICAL 



Item 


Standard 


Limit 


Voltage: 


12 V 


••• 


Ignition system: 
Ignition timing (B.T.D.C.) 
Advancer type 


10° at 1,150 r/min 
TPS and electrical type 


••• 
••• 


Voltage regulator: 
Type 

Model/manufacturer 
No load regulated voltage 


Semi conductor-short circuit type 
SH650A-12/SHINDENGEN 
14.1 ~ 14.9 V 


••• 
••• 
••• 


Electric fan: 
Model/manufacturer 


NAAF20/NIPPONDENSO 


••• 




CARBURETOR 



CARB 


7 



CARBURETION 
CARBURETOR 

FUEL LEVEL ADJUSTMENT 

1. Measure: 
• Fuel level® 




Fuel level: 

15.8 ~ 16.8 mm 

(below the MIKUNI mark) 



Out of specification -► Adjust. 
NOTE: 



Adjust the float level by slightly bending the float 
tang©. 



Fuel level measurement and adjustment 
steps: 

• Place the motorcycle on a level surface. 

• Use a garage jack under the engine to ensure 
that the carburetors are positioned vertically. 

• Connect the fuel level gauge (2) to the drain 
pipe. 






Fuel level gauge: 
90890-01312 



•Loosen the drain screw. 

•Hold the gauge vertically next to the MIKUNI 

mark (3). 
• Measure the fuel level (a) with the gauge. 



-5- 



TDM850 '97 WIRING DIAGRAM (EXCEPT FOR CH, A) 



® 




-i r^ 


J 


s 






G 


Dfl 


Dg 


G 


Y 


Ch 


Ch 


Y 


B 


L/R 


L/R 


B 




BROWN) 






BROWN 




Headlight lead 


Wire harness 




fa 

€1 
$i 
fa 
fa 

<l 
fa 
fa 
fa 



A.C. magneto/pickup coil 

Rectifier/regulator 

Main switch 

Battery 

Main fuse 

Starter relay 

Starter motor 

Starting circuit cut-off relay 

Gear position switch 

Sidestand switch 

T.P.S. (throttle position sensor) 

Ignitor unit 

Ignition coil 

Spark plug 

Accessory coupler 

Thermo unit 

Meter assembly 

Tachometer 

Water temperature meter 

Meter light 

Neutral indicator light 

High beam indicator light 

Turn indicator ligh 

Rear flasher light 

Front flasher light 

Headlight 

Diode 

Auxiliary light 

Left handlebar switch 

Horn switch 

Horn 

Lights switch 

Dimmer switch 

Pass switch 

Turn switch 

Flasher relay 

Clutch switch 

Fan motor 

Thermo switch 

Radiator fan fuse 

Tail/brake light 

Headlight fuse 

Rear brake switch 

Signal system fuse 

Right handlebar switch 

Front brake switch 

Engine stop switch 

Start switch 

Ignition fuse 



COLOR CODE 



R 


. . Black 


L ... 


. . Blue 


Y .... 


. . Yellow 


Br/W 


. . Brown/White 


L/W . 


. Blue/White 


Rr 


. . Brown 


Lg.. 


. . Light green 


B/L.. 


. . Black/Blue 


G/R . 


. . Green/ Red 


L/Y.. 


. Blue/Yellow 


Ch . 


. . Chocolate 


.. 


. . Orange 


B/R.. 


.. Black/ Red 


G/W. 


. . Green/White 


R/B.. 


. Red/Black 


Dg . 


. . Dark green 


R... 


.. Red 


B/W . 


. . Black/White 


G/Y . 


. . Green/Yellow 


R/W . 


. Red/White 


g 


. . Green 


Sb.. 


. . Sky blue 


B/Y.. 


. . Black/Yellow 


L/B.. 


. . Blue/Black 


R/Y.. 


. Red /Yellow 


Gy . 


. . Gray 


W .. 


. . White 


Br/L . 


. . Brown/Blue 


L/R.. 


. . Blue/Red